Electric generator



July 13, 1937. c. e. JONES 2,087,227

ELECTRIC GENERATOR Filed Jan. 17, 1934 5 Sheets-Sheet 1 July 13, 1937. c. G. JONES ELECTRIC GENERATOR Filed Jan. 17, 1954 3 Sheets-Sheet 2 July 13, 1937. c JONES 2,087,227

ELECTRIC GENERATOR Filed Jan. 17, 1934 3 Sheets-Sheet 3 serious.

of large direct currents.

atented July 13, 19E?"- Carl Jones, Ohio, assignor, by

mesne assignments, to Direct Current Welding @ompany, a corporation of Delaware Application January 17, 1934, Serial No. 06,960

1 @laim.

My invention relates to an electric generator specially adapted for welding and, in particular, to the continuous welding of metallic lengths by the resistance method, or a combination of the dash and resistance methods. Certain features described herein are covered in a divisional application Ser. No. 23,856, filed March 28, W85, carved herefroin.

Alternating current has been Widely used for electric welding with considerable success. The advantage of alternating current is that the necessary control operations can be e'fiected on the high voltage side of step-down transformers supplying the welding current. Because of the smaller current on the high voltage side of the transformers, the problems of control are not An objection to alternating current for welding, however, is that the weld is not ahsoy uniform but tends to follow the variations current alternations.

it has not been thought possilole heretofore to use direct currents of any considerable magnitude for electric welding because oi" the difficuities involved in the generation and control Direct-current gener store. of the shunt or compound type pmticularly, are unsuited to electric welding, first, hecause the commutation of heavy currents is at tended with great difiiculty, and second, because the shunt generator has a drooping voltage characteristic and it is not practical to provide a series or compound winding of suificient size to carry the large currents necessary for welding through a compound winding to overcome the drooping characteristic of the shunt generator in the known manner. The'drooping characteristic of a shunt generator would be even more noticeable when the generator is connected to a welding' load, than otherwise, because of the large currents required.

For the reasons'stated above, it has been thought heretofore impossible to use a self-excited, direct-current generator for supplying welding current and in the U. S. Patent to Sykes No. 1,920,900, there is described and claimed the use of a separately excited generator for directcurrent welding. Another difficulty attendant upon the use of direct current for welding is the control of the heavy currents required. It has been proposed heretofore to control these currents indirectly by controlling the excitation of the generators producing them. This is somewhat similar to the idea of controlling mternating welding current on the highwoltage side of the welding transiormgers, but is objectionable because of the time lag involved. The voltage required for welding is usually comparatively low and this fact further militates against self-excitation of the generator, since generator field windings are usually wound for a voltage higher than that generally employed in welding.

i have invented a generator adapted for electric welding which makes it possible to use direct current satisfactorily and, at the same time, to overcome the above-mentioned objections existent heretofore. In accordance with my invention, I provide direct-current generator capabio of generating large currents at relatively low voltage. 1 preerably employ a generator of the homopolar type. The generator has exciting windings for producing the necessary electromagnetic field these windings are excited by current induced in the generator armature on rotation thereof, either in the same means which induces the main power or welding current, or in a separate inducing ineans supplying current to the exciting windings only. The power terminais of the generator are brought out adjacent one end thereof and leads of opposite polarity are interleaved from the generator terminals to a pair of welding electrodes adapted to progressively engage the continuously advancing material to he welded. In the present description, I

shall explain the invention as applied to the welding of tubular blanks to form pipe, and the electrodes are preferably a pair of grooved discs disposed substantially at the same horizontal level with their axes substantially parallel and vertical.

E provide a multiple contact switch in the main welding circuit adaptedto close and open to initiate and terminate the flow of Welding current. The field windings of the generator are excited continuously so that there is no delay in the starting of the welding operation.

I also provide a system for automatically con trolling the generator excitation so as to maintain the proper welding voltage at all times and, at the same time, effective to cause the building up of the generator voltage promptly by overexcitation of the field during the starting period.

For a complete understanding or" the invention, reference is made to the accompanying drawings illustrating a present preferred embodiment of the invention and the method of its practice and certain modifications thereof. In the drawings:

Figure l is a side elevation with parts in section, showing a portion of the generator, the welding electrodes, and the connecting circuit and control switch therebetween;

Figure 2 is an end elevation of the generator from the left thereof as shown in Figure 1;

Figure 3 is a partial sectional view along the line III-III of Figure 1, illustrating a detail of the connecting circuit;

Figure 4 is a vertical axial section through the generator, certain parts being rotated from their normal position into the plane of section for the sake of clearness;

Figure 5 is a sectional view along the line V-V of Figure 4; t

Figure 6 is a sectional view similar to Figure 4 showing a. modification;

Figure '7 is a schematic diagram of connections illustrating the automatic control of the excitation to maintain the desired welding voltage and provide for accelerated building up of the welding voltage when starting; and

Figures 8 and 9 are similar to Figure '7, showing modified forms of connections.

Referring now in detail to the drawings, the generator II] has a frame II composed of a central annular yoke I2 and arms I3 extending axially thereof. The arms I3 merge into end rings l4.

An armature I5 extends axially of the yoke and end rings for rotation therein. The armature preferably is composed of cast steel and has journals I1 formed thereon for seating in bearings I8. Fluid supply means I9 are provided for cooling the armature. The armature I5 is provided with an inductor 20 which may be in the form of a conducting sleeve of copper, for example. Groups of brushes 2I and 22 are supported in any convenient manner, adjacent opposite ends of the inductor and have sliding, conducting engagement therewith. As indicated in Figure 2, there are groups of brushes of both polarities between each pair of adjacent arms I3. Terminals 23 and 24 extend radially from the brush groups 2I and 22, respectively. Leads 25 and 26 extend axially of the generator, as shown in Figure 4, and then radially thereof, as shown in Figure 2, the leads 25 from the terminals 23 extending through suitable openings 21 in the yoke I2.

As shown in Figure l, the terminals 25 and 25 extend radially of the generator sufllciently to clear the end rings and then laterally to a pair of welding electrodes 28 suspended for rotation in a horizontal plane from a crosshead 23 supported on housings 30. Pressure rolls 3! journaled vertically on a base 32, which is slidable horizontally relative to the housings 30, cooperate with the electrode rolls 28 to form a welding pass for tubular blanks having an axial seam cleft. The blanks are positioned before entering the welding pass so that the edges of the seam cleft engage the electrode rolls respectively.

A switch as is located adjacent the generator III and is connected in circuit with the leads 25.

fixed contacts 36. A housing 42 encloses the -working parts of the switch.

to the welding electrodes being insulated from each other by air spaces or solid insulation. This arrangement of the leads reduces the inductance of the welding circuit and, therefore, shortens the time necessary for the welding current to build up to full value after the closing of the switch 33. The decay of the current after opening the switch is correspondingly accelerated.

The generator I0 is provided with field windings 43 embracing the arms I3 for inducing the field flux radially through the yoke I2 and axially of the armature I5. Auxiliary field coils 44 are also provided for a purpose to be explained later.

Referring particularly to Figure 4, the armature I5 is provided, in addition to the inductor 20, for inducing the main power or welding current, with a plurality ofinductors 45. These inductors are positioned in slotted holes extending axially of the armature and are insulated therefrom. Slip rings 46 and. 41 are carried by the armature I5, insulated from each other and the armature. Brushes 46 and 43 cooperate with the slip rings, being supported in any convenient manner. Cross connections 50 extend between the brushes 48 and 49.

The inductors 45 are connected in series, in groups, by the slip rings, brushes and cros connections. It will be noted that the inner slip ring 46 is connected to the right-hand field winding 43. The inner slip ring 41 is connected to the middle slip ring 46 by a cross connection 53.

Similarly, the inductor 45 adjacent that shown in full lines in Figure 4 is connected to the middle slip ring 46 and also to the middle slip ring 41. From the latter, a cross connection extends to the outer slip ring 46. The second inductor 45 from that shown in full lines in Figure 4, is connected to the outer slip ring 46 and the outer slip ring 41. A connection extends from the latter to the left-hand field winding 43. The two field windings 43, shown in Figure 4, are connected in series with a control rheostat 5I.

From the foregoing, it will be apparent that three of the inductors 45 are connected in series to generate the voltage to send current through the windings 43. A three-turn armature winding is thus provided for each pair of exciting windings 43. A larger number of turns in the inducing winding could be employed by using additional slip rings and brushes. In this way, it is possible to obtain almost'any desired voltage for the field windings.

The induction of the main power or welding current requires no explanation. It will be understood that the field flux extends radially from the yoke I2 to the armature I5 and axially thereof, returning to the yoke through the end blocks I6, rings I4 and" arms I3. The rotation of the inductor 20 in the air gap between the yoke I2 and the armature I5 generates a voltage between the brushes 2| and 22, due to the movement of the elements of the inductor sleeve 20 through the flux crossing the air gap. Similarly, the inductors 45 induce the necessary exciting voltage.

A modification of the invention is shown in Figure 6. This modification is similar in general to that of Figure 4, except as to the manner of obtaining the exciting current for energizing the field windings 43'. In the modification of Figure 6, separate brushes 52 are supported in any convenient manner for engaging the inductor 20 in the same manner as the brushes 2| and 22. The brushes 2| and 22' of Figure 6 are shown as supported on brackets 53. They could, of course, be positioned inside the brushes 52 at about the position indicated in Figure 4. It will be obvious that the windings 43' must be designed for the voltage between the brushes 52 and will thus be composed of conductors of greater total cross-section than the windings 43, which are designed for a multiple of that voltage. The chief advantage of this modification is that the general construction is simpler than that of Figure 4. In both forms of the generator, however, the voltage on the field changes very slightly on the application of full load to the generator. The machines have substantially the characteristics of separately excited generators, although they are obviously self-excited. The field voltage is not decreased because of an increased IR drop in the brushes and the sliding contacts, as the load is applied. A substantially uniform excitation is thus attained, regardless of the magnitude of the generator load.

Figure 7 illustrates the voltage control system which I prefer to employ in connection with the apparatus described above. As shown in Figure "Z, the main field windings '53 are connected across a pair of brushescorresponding either to the outer brush ll and the inner brush @6, or to the brushes 52. The auxiliary difife'rential field windings M are connected in series with a control rheostat 53 across the leads 25 and 26. The windings it, however, oppose the effect of the windings t3, since the corresponding ends of the windings, as shown in Figure 7, are connected to opposite ends of the generator iii. A field relay at has its contact connected in series with the winding it and the rheostat 53, the winding of the relay being connected across the leads 25 and for a purpose which will presently apthat when the generator is operating under load, the net effect of the two will be sufficient to main tain the desired welding voltage. When the load. on the generator is removed by the opening of the switch 33, there will be a tendency for the terminal voltage of the generator to rise. tiny increase in the terminal voltage of the mahowever, would increase the energization of the bucking windings M, which would tend to decrease the excitation and, therefore, the terminal voltage of the machine maintains a substantially uniform voltage from full load to no load. The reverse occurs on application of the load, that is, the tendency for the terminal voltage of the machine to drop is compensated for by the decreased excitation of the bucking windit. The relay 54 is designed to hold its contact closed when the voltage across the terniinals 25, 26 exceeds a predetermined value, in

the neighborhood of normal operating voltage.

When the generator Ill is being started out from rest, being driven by a variable speed motor or other suitable source of power, there will initially be no voltage across the leads 25 and The contacts of the relay 54 will therefore be open, opening the circuit of the bucking field windings M. As the generator armature is accelerated to normal speed, the residual magnetism of the yoke i2 will induce a slight voltage between the brushes to which the windings 53 are connected. Since all the turns of the windlugs 53 are now effective, the windings H be- The windings i3 and M are designed so.

ing disconnected, the nonnal voltage of the machine develops rapidly and, when substantially normal voltage has been reached, the relay 54 operates to energize the windings 44 to prevent over-excitation of the generator.

In accordance with my invention, I advance metal lengths, such as tube blanks to be welded, into engagement with the electrodes 28 while the switch 33 is open, the generator being driven at normal speed, fully excited. Under these conditions, suificient voltage appears across the generator leads to start the flow of welding current immediately on closing the switch 33. There is some delay in the building up of the welding current because of the inductance of the welding circuit. This delay, however, is comparatively short compared to that necessary for the voltage of a generator to build up, as required by systems which rely on. generator field control for initiating and terminating the flow of welding current. I It will be obvious that the inductance of a generator field winding is far greater than that of the Welding circuit shown in Figures 1 and Practically, a field switch cannot be used with a homopolar generator, due to the excessive length of time it takes to build up. To use a field switch with a homopolar generator for interrupting the current from the electrodes would be impossible since a 50 skelp length traveling 60 a minute would be through the welder before the current could build up. For this reason, such a construction is practically out of the question. The importance of the prompt building up of the welding current, of course, is that the blanks must be moved forward at a more or less uniform rate, and the higher the rate, the greater the output per day and the better the weld. Any delay in building up the welding current, therefore, increases the end scrap loss, that is, the portion of the blank at either current motor '55 having a shunt field winding 58, a field rheostat and a series field winding 555. The armature leads indicated at and the shunt field circuit are connected to a direct current source indicated at ca The variable speed motor driving the gencontrolled by varying the speed at which the generator is driven. The possibility of reducing the generator speed under certain conditions, lurtherinore, avoids a certain amount of brush wear which would be encountered ii a constant speed motor were employed.

Figure 9 is similar to Figure 8 except that the bucking field winding instead of being con: nected across the generator it, has one end connected to one generator terminal and the other end connected to the main lead 25 at a point be-= yond the switch 33 and is thus eilective only when the switch is closed. This occurs, of course, only after the tube is in contact with the electrodes.

The open circuit voltage across the generator will naturally be considerably higher than the welding voltage proper. Thus when the switch 33 is closed and the relay ii i is adjusted for a slight delay in closing, atemporary overvoltage will be available in the system shown in Figure 9 to hasten the rise of the welding current to full value. For this remon, the scheme of connections shown in Figure 9 is preferred to that of Figure 8 since it will cause quicker heating oi the stock being welded. The system of Figure 8 tends to maintain a constant voltage regardless of the load on the generatori It will be apparent from the foregoing description that my invention makes possible the use oi! direct current for welding heavy material at a high rate of speed. The homopolar generator is well adapted to the delivery 01' large currents at low voltage. According to my invention, furthermore, the generator is self-excited, avoiding the necessity for a separate generator or other source of exciting current. At the same time. the characteristics of the generator 01' my invention are substantially those of a separately excited machine. By maintaining the generator voltage constant during welding. welding current is in itiated with a minimum delay, reducing the end scrap loss to a substantially negligible amount. The interleaving oi the welding circuit between the generator and the electrodes further reduces the delay in building up the welding current. The generated voltage changes very little from no load to full load because the exciting current is either derived from a separate armature winding or collected from the armature directly and not through the main power brushes. The field current is thus not greatly aflected by the flow of the power current. The difierential field windings provide substantially the characteristics of a cumulative compound generator since they maintain the terminal voltage substantially the same at no load and full load. These windings also tend to overcome the effect of any tendency of the terminal voltage to drop on closing of the main switch, thus further accelerating the building up of the welding current to its full value. There is no time lag involved as in the case of mechanically operated correcting devices. The correction commences as soon as the load is applied.

Although I have illustrated and described herein but one preferred embodiment of the invention and method 01' its practice, with some modifications thereof, it will be apparent that numerous changes in the construction and operation described may be made without departing from the spirit of the invention or the scope of the appended claim.

I claim:

The combination with a homopolar generator including a field structure, an armature rotatable therein, an inductor on the armature wherein the field induces the main power current, and conductors for delivering said current to a load, of a winding for exciting said field structure, an

inducing winding on said armature for supplying CARL G. JONES. 

